A composite panel for making a wall of a building includes an outer cladding plate, an inner wall plate, and a supporting structure provided between the outer cladding plate and the inner wall plate and which is partially embedded in a polymer foam.
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30. A composite panel for making a wall of a building, comprising:
an outer cladding plate;
an inner wall plate;
a supporting structure provided between the outer cladding plate and the inner wall plate and at least partially embedded in a polymer foam;
at least one panel made from mineral wool housed in the supporting structure;
two side edges, at least one of the two side edges being configured to cooperate with the side edge of an adjacent panel configured in a complementary manner
wherein the polymer foam includes a polyurethane foam having a density greater than 30 kg/m3;
wherein the supporting structure includes a metal frame including at least two side posts, an upper crosspiece, and a lower crosspiece; and
wherein at least one side edge is formed by the polymer foam gripped between the outer cladding plate and the inner wall plate.
1. A composite panel for making a wall of a building, comprising:
an outer cladding plate;
an inner wall plate;
a supporting structure provided between the outer cladding plate and the inner wall plate and at least partially embedded in a polymer foam, a first side of the supporting structure facing the inner wall plate is secured to the inner wall plate;
at least one panel made from mineral wool housed in the supporting structure;
wherein the polymer foam includes a polyurethane foam having a density greater than 30 kg/m3;
wherein the supporting structure includes a metal frame including at least two side posts, an upper crosspiece, and a lower crosspiece;
wherein the supporting structure is covered with the polyurethane foam on a second side facing the outer cladding plate, the polyurethane foam extending to lateral sides of the supporting structure, extending between the first and the second sides of the supporting structure; and
wherein on a side opposite the supporting structure, the polyurethane foam is in contact with a layer of mineral wool which is glued to the outer cladding plate.
29. A method for making a composite panel, comprising:
arranging at least one inner wall plate, on which a supporting structure is placed or secured, in a molding frame;
positioning side crosspieces with shapes complementary to those of the side edges of the panel to be made;
placing polymer foam blocks on the inner wall plate or the supporting structure;
positioning at least one panel made from mineral wool in the supporting structure;
placing an outer cladding panel on the polymer foam blocks so that the outer cladding panel is positioned at a certain distance from the supporting structure;
inserting an assembly of the inner wall plate, the supporting structure, the side crosspieces, the polymer foam blocks, and the outer cladding panel into a conformator;
hot injecting the polymer foam; and
stripping the panel after cooling
wherein the composite panel comprises:
an outer cladding plate;
an inner wall plate;
a supporting structure provided between the outer cladding plate and the inner wall plate and at least partially embedded in a polymer foam, a first side of the supporting structure facing the inner wall plate is secured to the inner wall plate;
at least one panel made from mineral wool housed in the supporting structure;
#30# wherein the polymer foam includes a polyurethane foam having a density greater than 30 kg/m3;wherein the supporting structure includes a metal frame including at least two side posts, an upper crosspiece, and a lower crosspiece;
wherein the supporting structure is covered with the polyurethane foam on a second side facing the outer cladding plate, the polyurethane foam extending to lateral sides of the supporting structure, extending between the first and the second sides of the supporting structure; and
wherein on a side opposite the supporting structure, the polyurethane foam is in contact with a layer of mineral wool which is glued to the outer cladding plate.
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The present invention relates to a composite panel for making a wall of a building.
The outer walls of buildings, and in particular of buildings such as individual houses, are traditionally made up of concrete block walls assembled and supported by cement. This traditional construction technique has the drawback of requiring significant labor and calling on several building trades, which represents drawbacks in terms of the assembly time for such walls as well as the cost.
Example embodiments of the present invention resolve these drawbacks by providing building wall elements that can be assembled easily, while having mechanical properties adapted to all of the constraints placed on the buildings.
To that end, example embodiments of the present invention provide a composite panel for making a wall of a building, including an outer cladding plate, an inner wall plate, and a supporting structure provided between the outer cladding plate and the inner wall plate, whereof the supporting structure is at least partially embedded in a polymer foam.
The panel can also include the following optional features, considered alone or in combination:
Example embodiments of the present invention provide a method for making a composite panel as previously defined, including at least the following steps:
at least one inner wall plate, on which a supporting structure is placed or secured, is arranged in a molding frame,
side crosspieces with shapes complementary to those of the side edges of the panel to be made are positioned,
polymer foam blocks placed on the inner wall plate or the supporting structure are positioned,
an outer cladding panel placed on the foam blocks so that the outer cladding panel is at a certain distance from the supporting structure is positioned,
the assembly thus formed is inserted into a conformator,
the polymer foam is injected hot, and
the panel is stripped after cooling.
Example embodiments of the present invention will now be described more precisely, but non-limitingly in light of the appended figures.
The composite panel, generally referenced 1 in
The outer cladding plate 2 is for example a plate made from lacquered or pre-lacquered galvanized steel with a thickness for example between 0.5 mm and 1.5 mm. Such a lacquered metal cladding plate is known in itself. The inner wall plate 3 is, as better visible in
In reference to
Each of the posts 43, 44 is formed, as shown in
The different profiles and the wind bracing elements of the frame are for example formed by galvanized or non-galvanized steel, with a thickness preferably between 1.5 and 3 mm, and are for example assembled by spot welding.
Moreover, and as shown in
As shown in
In order to ensure the connection of the assembly and also to obtain satisfactory mechanical strength of the panel, the supporting structure 4 is embedded in a polymer foam 5 which is, for example and preferably, polyurethane foam whereof the density is preferably greater than 30 Kg/m3, and better between 40 Kg/m3 and 50 Kg/m3. Moreover, the foam is chosen so that its coefficient λ of thermal conductivity is less than 0.035 W/m2·K. The polyurethane foam, in which the supporting structure is embedded, comes into contact with the inner wall plate and into contact with the outer cladding plate such that the inner cladding and inner wall plates are glued by this foam and thus form a panel whereof the various components are integral with each other.
Due to the presence of this high-density polymer foam 5, the mechanical strength of the panel is considerably increased relative to panels with an identical shape but not comprising a polymer foam 5. Indeed, for a panel with a height between 2 meters and 4 meters and a width between 900 mm and 1m50, for example, and the thickness of which is between 150 mm and 300 mm, the resistance to longitudinal compression forces allows it to react a vertical load greater than 300 kN, whereas a panel whereof the framework is not embedded in foam can only react a distributed load in the vicinity of 40 kN. Moreover, such a panel can bear a load distributed on its outer surface in the vicinity of 60 kN.
Moreover, the upper and lower edges of the panel, as well as the side edges, have shapes adapted to allow the assembly of the panels in a structure.
Thus, along the upper edge 10 of the panel, the upper crosspiece 41, i.e. the upper edge of the supporting structure, extends upwards beyond the upper edge 30 of the inner wall plate 3 as well as beyond the upper edge of the outer cladding plate 2. This arrangement allows fitting in a suitable structure with a shape complementary to the shape of the upper crosspiece 4.
In the lower portion 11 of the panel, the lower crosspiece 42, i.e. the lower edge of the supporting structure, extends beyond the lower edge 31 of the inner cladding plate 3, which leaves available space 423 to arrange a transverse raceway for running cables in which the connecting opening 422 with the raceway for running cables incorporated into the panel emerges. Moreover, the outer cladding plate 2, as well as its polymer foam coating, extends downwards beyond the lower crosspiece 42, i.e. the lower edge of the supporting structure, so as to form a covering skirt 21 that for example makes it possible to cover the edge of a lower support structure of the panel. Furthermore, along the lower crosspiece 42, on the side opposite the outer cladding plate 2, the polymer foam 5 includes a slot 22 that extends over the entire width of the panel and is adapted to receive, for example, the wing of a profile making up a bearing structure of the lower surface of the lower crosspiece 42 of the supporting structure of the panel. Thus, this slot allows assembly and proper fastening of the panel on a wall element.
The panel just described includes an inner wall plate made up of a plaster plate. However, it may be desirable to improve the insulation capacity, in particular stereophonic, of such a wall. To that end, it is possible to provide, as shown in
Moreover, a steam-impermeable membrane 32, also called vapor barrier, is adhered on the inner surface of the outer plaster plate. This membrane, which is not essential, is for example made up of an aluminum sheet.
The layer of fibrous material can have a thickness between 10 and 50 mm, each 10 mm slice of glass or rock wool increasing the transmission loss value by 1 decibel. In that case, and as shown in the figure, the raceway 6′ is no longer incorporated into the framework in the supporting structure 4 of the composite panel, but is inserted inside the layer of fibrous material. As a result, the top and bottom of the panel are adapted so that this raceway emerges in a zone where it is possible to run cables at a distance relatively close to the plaster plate.
The two panels just described, with or without fibrous material, are well suited to making walls for single-family homes. However, to make multi-family homes, i.e. including several adjacent residences, it may be desirable to increase the properties, in particular the fire resistance of the walls. To that end, as shown in
For such panels, the fire performance was evaluated and is in the vicinity of 30 nm of resistance for a normalized fire. The conductivity of the base panel, i.e. without rock or glass wool, is 0.248 W/m2·K.
Moreover, it will be noted that the plaster tabs 323, 323B intended to cover the seams of two adjacent panels in order to improve the fire resistance of an assembly of panels, are not necessarily made from plaster. These tabs may be made up of any material having fire resistance properties at least equal to those of the plaster, and preferably easier to implement than plaster. Thus, the tabs are fire resistant tabs.
We will now refer to
In this panel 1AA, the supporting structure 4A includes a metal frame including two side vertical posts 43A, 43A′ and a central vertical post 45A that are connected at their upper portions by an upper crosspiece 41A and a lower crosspiece not shown in the figures.
The side vertical posts 43A, 43A′ are each respectively made up of two profiles 441A, 442A; 441A′, 442A′ positioned in the same manner as the profiles 441 and 442 of the supporting structure 4 of
The central vertical post 45A is made up of two C-shaped profiles 445A, 454A bearing in contact back to back.
The supporting structure 4A also includes a metal wind bracing plate 46A secured to the side vertical posts 43A, 43A′ and the central vertical post 45A, for example by screwing. This metal wind bracing plate 46A is substantially planar and has, at each of its ends, a recess 47A, 47A′ so as to fit the recess formed by bringing the profiles 441A, 442A; 441A′, 442A′ of the side vertical posts 43A, 43A′ alongside each other.
This supporting structure 4A is secured, for example by screwing, to a plaster plate 48A of the same nature as that of the first two example embodiments, also including a tab 481A corresponding to the tab 323 previously described and thereby making up the inner wall plate.
The supporting structure 4A is embedded in the polyurethane foam 49A, also of the same nature as that previously described, which comes into contact with the plaster plate 48A at the side edges of the panel 1AA.
On the side opposite the plaster plate 48A, the polyurethane foam 49A, with a thickness of about 7 cm, is in contact with a layer of rock wool 50A that is stuck to the outer cladding plate 51A. Between the rock wool 50A and the polyurethane foam, metal protective plates 58A are provided at the upper and lower ends of the panel that protect the rock wool and increase the strength of the skirt.
Within the supporting structure 4A, two rock wool panels 52A, 52A′ are each inserted between two facing profiles of two adjacent posts, such that the two ends of each of the two rock wool panels 52A, 52A′ are housed in the bottom of two facing profiles 442A, 445A; 454A, 441A′.
Furthermore, two strips of rock wool 53A and 53A′ are respectively slid into each C-shaped profile 441A, 442A′ of the side vertical posts, which are oriented towards the outer metal cladding 51A.
In this example embodiment, the cables are not run in a raceway, but in a space provided between the plaster plate 48A secured to the supporting structure 4A that is kept at a certain distance from a plaster finishing plate 54A using spacers 551A, 552A, 553A, 554A secured to two plaster plates 48A and 54A.
Among the four spacers 551A, 552A, 553A, 554A each in the shape of a C, two central spacers 552A, 553A bear in contact back to back and two side spacers 551A, 554A are each arranged at one end of the plaster plates 48A and 54A, while being oriented towards the central spacers 552A, 553A.
This configuration makes it possible to insert, between the two plaster plates 48A and 54A, two glass wool panels 56A, 56A′ whereof each end is housed in the bottom of two adjacent and facing U-shaped spacers.
Each spacer 551A, 552A, 553A, 554A is asymmetrical in that the branch of the C of each spacer that is against the plaster plate 48A secured to the supporting structure 4A is longer than the branch secured to the plaster finishing plate 54A. This configuration makes it possible to screw, in a single operation, the spacers 551A, 552A, 553A, 554A on the side of their longest branch, a vapor barrier sheet 57A, and the plaster plate 48A to the supporting structure 4A without being bothered by the opposite branches of the spacers.
In this manner, the cables can be inserted into the rock wool panels. If the position of the switch is not known before assembly, the cables will be slid on the worksite into the rock wool panels up to the desired point. If the position of the switch is, however, known, the cables will be suitably installed and may emerge in a space formed in the plaster finishing plate 54A to receive a switch that will be mounted on the worksite.
The insertion of the mineral wool panels into the supporting structure is completely advantageous, since it makes it possible to group together, in a same volume, the functions unique to the mineral wool and the supporting structure, while participating in the mass-spring-mass effect for the acoustical resistance. This advantage can be transposed to the insertion of mineral wool panels between the spacers, the possibility of sliding the cables into the wool being added to the other advantages.
In this manner, a panel is obtained having a suitable thickness and for which all of the properties required to build multi-story single-family and multi-family homes are high performing.
The mechanical strength of the panel is imparted mainly by the supporting structure 4A, which is embedded in the polyurethane foam.
Furthermore, this supporting structure has several advantages.
First, the posts impart vertical stability and their C shape allows the mineral wool panel to be inserted into the thickness of the supporting structure with the previously mentioned advantages. In this respect, it is possible to provide only side posts and no central post. This would then result in the presence of a single rock wool panel.
Furthermore, using a metal plate as the wind bracing element makes it possible to give this plate, in addition to the wind bracing function, an anti-housebreaking function.
Moreover, the vapor barrier sheet 57A participates in the wind bracing and the outer cladding plate 51A also participates in the mechanical strength of the panel.
The fire resistance is imparted mainly by the plaster plate 48A secured to the supporting structure 4A and its firewall tab 481A, the plaster finishing plate 54A as well as the joint presence of the rock wool layer 50A adhered to the outer cladding plate 51A (outer fire performance) and the panels 52A, 52A′ and strips 53A, 53A′ of rock wool positioned in the supporting structure 4A.
The thermal insulation comes from the polyurethane foam, the panels 52A, 52A′ and strips 53A, 53A′ of rock wool positioned in the supporting structure 4A and the rock wool layer 50A adhered to the outer cladding plate 51A.
Regarding acoustic performance, the presence of three layers of mineral wool between which dense materials are located makes it possible to optimize the mass-spring-mass effect and to impart good acoustic performance.
It will also be noted that the rock wool layer 50A adhered to the outer cladding plate 51A is stiff enough to ensure the flatness of the outer cladding plate 51A.
All of the performances, and in particular the thermal insulation, must be kept at a maximum at the seam between two adjacent panels. This is why the edges of the panels are configured in a particular manner.
As previously indicated, the side edges 12, 13; 59A, 59A′ of the panel according to any of the example embodiments previously described are configured so as to allow assemblies of adjacent panels. To that end, the edges of the panels are configured so as to have either male or female shapes, and complementary to each other so that a male edge of one panel can adapt on a female edge of another panel. Moreover, male and female edges are provided making it possible to assemble panels in a same plane or perpendicular panels.
For clarity, the references used in the continuation of the description are those that appear in
The male edge 13B, shown in
Moreover, and as also shown in
Moreover, along the side edges of the plaster plate, a thinner strip 321 or 322 extends over the outer surface of the panel, retracted towards the inside of the panel. This thinner strip extending over the entire height of the plaster plate along a side edge is intended to receive tape making it possible to hide the seam between two plaster plates of adjacent panels.
In order to be able to make corner assemblies, the panels can also include male or female corner edges.
The portion 121 B of the outer cladding plate and its polymer foam coating 5 that extends beyond the side edge of the inner wall plate, has one surface 122B facing the inside of the panel that is configured to have a shape complementary to a male edge of a panel as previously described. To that end, this portion 121B includes grooves that extend over the entire height of the panel and that have shapes identical to those of the grooves of the female edges previously described.
As shown in
In the two cases of corner edges, male or female, the outer cladding plates that extend beyond the side edge of the inner wall plate, extend laterally over a distance suitable for covering the edge of an adjacent panel perpendicular to the composite panel.
Lastly, and as shown in
The general principle for manufacturing a composite panel according to example embodiments of the present invention is as follows. At least the inner plaster plate, on which the supporting structure is placed or has been secured beforehand, is positioned in a mold frame. Side crosspieces with shapes complementary to those of the side edges of the panel to be made are positioned in this same frame. Polymer foam blocks are positioned on the supporting structure 4A or on the plaster plate in the case of the first two example embodiments and the outer cladding panel is placed on the foam blocks.
In the case of the third example embodiment of
The assembly thus formed is introduced into a conformator, in which polymer foam is injected hot, and the panel is stripped after cooling.
Regarding the embodiment of
Then, the spacers, the vapor barrier sheet, and the outer plaster plate are all secured in a same screwing operation to the supporting structure 4A and more particularly to four of the profiles of the supporting structure.
Then, the glass wool panels are positioned between the spacers and the plaster finishing plate on at least one of the spacers.
This assembly is then positioned in the mold frame and the molding operation is done as previously described.
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